Molds having cooling behind insert technology and related methods

ABSTRACT

This disclosure includes injection molds for reducing cycle times and related methods. Some molds include first and second mold portions movable relative to one another from an open position to a closed position in which each of one or more recesses of the first mold portion cooperates with a respective one of one or more recesses of the second mold portion to define a chamber. Each of the chamber(s) includes a first cooling body coupled to the first mold portion, a second cooling body coupled to the second mold portion, and first and second inserts removably coupled, respectively, to the first and second cooling bodies such that the inserts cooperate to define a mold cavity within the chamber that is configured to receive a thermoplastic material. Each of the cooling bodies has an inlet, an outlet, and a fluid cavity in fluid communication with the inlet and the outlet.

FIELD OF THE INVENTION

The present invention relates generally to injection molding machines,and more specifically, but not by way of limitation, to injectionmolding machines for forming one or more lenses and methods of using thesame.

BACKGROUND ART

Injection molding machines that can use interchangeable mold inserts canbe beneficial. For example, by using different inserts that are readilychangeable, a single injection molding machine can be used to makedifferent products. However, such inserts can inhibit heat transferbetween moldable material within the mold and other portions of themold, such as during cooling of the moldable material, therebyincreasing cycle times and decreasing productivity.

SUMMARY OF THE INVENTION

Accordingly, there is a need in the art for injection molding machinesthat use interchangeable mold inserts while mitigating increases incycle times typically caused thereby. Embodiments of the present moldsaddress the above-noted limitations of existing molds by providingcooling bodies to which interchangeable inserts can be attached. Suchcooling bodies can be used to cool moldable material injected into acavity defined by the mold inserts; for example, coolant can flowthrough a cooling body to promote improved heat transfer from themoldable material and through the insert attached to the cooling body.In some of the present molds, cooling bodies can be used with existingmold inserts. Additionally, some of the present cooling bodies arecompatible with molds having insert-eject functionality.

Some embodiments of the present molds comprise first and second moldportions, each having one or more recesses. For some molds, the moldportions are movable relative to one another between an open positionand a closed position. In some molds, when the mold portions are in theclosed position, each of the recess(es) of the first mold portioncooperates with a respective one of the recess(es) of the second moldportion to define a chamber. In some molds, each of the one or morechambers includes a first cooling body coupled to (but not unitary with,in some molds) the first mold portion and a second cooling body coupledto (but not unitary with, in some molds) the second mold portion. Insome molds, for each of the chamber(s), a first insert is configured tobe removably coupled to the first cooling body and a second insert isconfigured to be removably coupled to the second cooling body such that,when the first and second inserts are respectively removably coupled tothe first and second cooling bodies, the first and second insertscooperate to define a cavity within the chamber. Some molds comprise oneor more of the first inserts and one or more of the second insertswherein, for each of the chamber(s), one of the first insert(s) iscoupled to the first cooling body and one of the second insert(s) iscoupled to the second cooling body.

In some molds, each of the first and second inserts comprises siliconcarbide. In some molds, the mold cavity is configured to receive athermoplastic material.

In some molds, each of the first and second cooling bodies comprises athermally conductive material. In some molds, each of the first andsecond cooling bodies has opposing first and second faces, where thesecond face is configured to be removably coupled to (is coupled to, insome molds) one of the first and second inserts. In some molds, thefirst insert and the second insert are each configured to be in contactwith respectively the first cooling body and the second cooling bodyexclusively through the second face of respectively the first coolingbody and the second cooling body. In some molds, each of the first andsecond cooling bodies has an inlet and an outlet and defines a fluidcavity in fluid communication with the inlet and the outlet. In somemolds, for each of the first and second cooling bodies, the fluid cavityis closer to the second face than the first face.

In some molds, the chamber(s) comprise two or more chambers. In somemolds, for each of one or more sets of a plurality of the chambers, thefirst cooling bodies are in fluid communication with one another via oneor more first conduits. In some molds, for each of one or more sets of aplurality of the chambers, the second cooling bodies are in fluidcommunication with one another via one or more second conduits. In somemolds, each of the first conduit(s) has a first diameter and each of thesecond conduit(s) has a second diameter. In some embodiments, the seconddiameter is at least 20% larger than the first diameter.

In some molds, for each of the set(s) of chambers, the first coolingbodies are connected in parallel such that the inlet of each of thefirst cooling bodies is coupled to a common supply conduit in fluidcommunication with a fluid source and the outlet of each of the firstcooling bodies is coupled to a common exhaust conduit in fluidcommunication with an exhaust. In some molds, for each of the set(s) ofthe chambers, the second cooling bodies are connected in series suchthat a supply conduit in fluid communication with a fluid source iscoupled to the inlet of one of the second cooling bodies, an exhaustconduit in fluid communication with an exhaust is coupled to the outletof one of the second cooling bodies, and one or more conduits aredisposed between the second cooling bodies such that when fluid flowsfrom the supply conduit, the fluid flows consecutively through each ofthe second cooling bodies before flowing through the exhaust conduit. Insome molds, the mold comprises three or more of the chamber(s). In somemolds, at least one of the set(s) of the chambers comprises three ormore second cooling bodies connected in series. In some molds, theset(s) of the chambers comprise two or more sets of the chambers; insome of such molds, the second cooling bodies of at least one of thesets are not in fluid communication with the second cooling bodies ofother ones of the sets.

In some molds, each of the second cooling bodies is movable within arespective one of the recess(es) of the second mold portion between afirst position and a second position. In some molds, when one of thesecond cooling bod(ies) is in the second position, the second coolingbody is closer to the face of the second mold portion that, when themold portions are in the closed position, faces the first mold portionthan when in the first position.

Some embodiments of the present methods comprise moving a first moldportion and a second mold portion relative to one another from an openposition to a closed position. In some methods, the mold portionscooperate to define one or more chambers when in the closed position. Insome methods, each of the mold chamber(s) comprises a first cooling bodycoupled to (but not unitary with, in some methods) the first moldportion, a second cooling body coupled to (but not unitary with, in somemethods) the second mold portion, a first insert removably coupled tothe first cooling body, and a second insert removably coupled to thesecond cooling body such that the first and second inserts cooperate todefine a mold cavity. Some methods comprise, before moving the first andsecond mold portions, and for at least one of the chamber(s), decouplinga third insert from the first cooling body and a fourth insert from thesecond cooling body, and removably coupling the first insert to thefirst cooling body and the second insert to the second cooling body. Insome methods, the third and fourth inserts are configured to cooperateto define a mold cavity having a shape different from a shape of themold cavity defined by the first and second inserts. In some methods,the coupling is performed without placing the first and second insertsin fluid communication with the first and second cooling bodies. Somemethods include receiving, at each of the mold cavit(ies), athermoplastic material.

Some methods comprise cooling the received thermoplastic material withthe first and second cooling bodies. In some methods, each of the firstand second cooling bodies comprises opposing first and second faces andan inlet and an outlet. In some methods, for each of the first andsecond cooling bodies, the first face is coupled to one of the moldportions and the second face is removably coupled to one of the firstand second inserts. In some methods, each of the first and secondcooling bodies defines a fluid cavity closer to the second face than thefirst face. In some methods, cooling comprises, for each of the firstand second cooling bodies, receiving fluid at the inlet from a fluidsource, conveying the received fluid to the fluid cavity, conducting,through one of the first and second inserts, heat from the thermoplasticmaterial to the cooling body to heat the conveyed fluid, andtransmitting the heated fluid through the outlet and outside of thecooling body. In some methods, cooling comprises, for each of thechamber(s), receiving fluid at the inlet of the first cooling body at arate within 10% of the rate at which fluid is received at the inlet ofthe second cooling body. In some methods, cooling is performed until thethermoplastic material solidifies.

In some methods, the one or more chambers comprise two or more chambers.In some of such methods, cooling comprises receiving, at the inlet of atleast two of the first cooling bodies, fluid from a common supplyconduit. In some of such methods, cooling comprises conveying, to anexhaust, fluid from the outlet of at least two of the first coolingbodies along a common exhaust conduit. In some of such methods, coolingcomprises receiving, at the inlet of at least one of the second coolingbodies, fluid conveyed from the outlet of another one of the secondcooling bodies.

Some methods comprise moving the first mold portion and the second moldportion relative to one another from the closed position to the openposition. In some methods, for each of the second cooling bod(ies), thesolidified thermoplastic material is coupled to the second insert whenthe mold portions are in the open position. Some methods comprise, foreach of the second cooling bod(ies), moving the second cooling bodyrelative to the second mold portion. In some methods, each of the secondcooling bod(ies) is moved closer to the face of the second mold portionthat, when the mold portions are in the closed position, faces the firstmold portion. Some methods comprise, for each of the second coolingbod(ies), ejecting the solidified thermoplastic material from the movedsecond insert.

The term “coupled” is defined as connected, although not necessarilydirectly, and not necessarily mechanically. The terms “a” and “an” aredefined as one or more unless this disclosure explicitly requiresotherwise. The term “substantially” is defined as largely but notnecessarily wholly what is specified (and includes what is specified;e.g., substantially 90 degrees includes 90 degrees and substantiallyparallel includes parallel), as understood by a person of ordinary skillin the art. In any disclosed embodiment, the terms “substantially” maybe substituted with “within [a percentage] of” what is specified, wherethe percentage includes 0.1, 1, 5, and 10 percent.

The phrase “and/or” means and or or. To illustrate, A, B, and/or Cincludes: A alone, B alone, C alone, a combination of A and B, acombination of A and C, a combination of B and C, or a combination of A,B, and C. In other words, “and/or” operates as an inclusive or.

Further, a device or system that is configured in a certain way isconfigured in at least that way, but it can also be configured in otherways than those specifically described.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), and “include” (and any form of include, such as “includes”and “including”) are open-ended linking verbs. As a result, an apparatusthat “comprises,” “has,” or “includes” one or more elements possessesthose one or more elements, but is not limited to possessing only thoseone or more elements. Likewise, a method that “comprises,” “has,” or“includes” one or more steps possesses those one or more steps, but isnot limited to possessing only those one or more steps.

Any embodiment of any of the apparatuses, systems, and methods canconsist of or consist essentially of—rather thancomprise/have/include—any of the described steps, elements, and/orfeatures. Thus, in any of the claims, the term “consisting of” or“consisting essentially of” can be substituted for any of the open-endedlinking verbs recited above, in order to change the scope of a givenclaim from what it would otherwise be using the open-ended linking verb.

The feature or features of one embodiment may be applied to otherembodiments, even though not described or illustrated, unless expresslyprohibited by this disclosure or the nature of the embodiments.

Some details associated with the embodiments are described above andothers are described below.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings illustrate by way of example and not limitation.For the sake of brevity and clarity, every feature of a given structureis not always labeled in every figure in which that structure appears.Identical reference numbers do not necessarily indicate an identicalstructure. Rather, the same reference number may be used to indicate asimilar feature or a feature with similar functionality, as maynon-identical reference numbers.

FIGS. 1A and 1B are side views of an embodiment of the present moldswhen first and second portions of the mold are in the open configurationand the closed configuration, respectively.

FIG. 1C is a bottom view of the mold of FIGS. 1A and 1B when the firstand second mold portions are in the closed configuration.

FIG. 1D is a sectional view of the mold of FIGS. 1A and 1B, taken alongline 1D-1D of FIG. 1C when no inserts are attached to the cooling bodiesof the mold.

FIGS. 1E and 1F are, respectively, a top view of the first mold portionand a bottom view of the second mold portion of the mold of FIGS. 1A and1B when no inserts are attached to the cooling bodies thereof.

FIG. 2 is an enlarged sectional view of one of the chambers of the moldof FIGS. 1A and 1B when inserts are attached to the cooling bodiesdisposed therein.

FIG. 3A is a sectional view of the mold of FIGS. 1A and 1B when insertsare attached to the cooling bodies thereof, the first and second moldportions are in the closed configuration, and a moldable material isinjected into the mold cavities defined by the inserts.

FIG. 3B is a sectional view of the mold of FIGS. 1A and 1B when thefirst and second mold portions are in the open configuration after theinjected moldable material is solidified.

FIG. 3C is a sectional view of the mold of FIGS. 1A and 1B when thecooling bodies of the second mold portion are moved such that theinserts attached thereto extend partially beyond the face of the secondmold portion to eject the solidified moldable material.

FIG. 4A is a sectional view of the mold of FIGS. 1A and 1B taken alongline 4A-4A of FIG. 1B, where the outlines of the cooling bodies disposedin the recesses of the first mold portion are shown with dashed lines.

FIG. 4B is a sectional view of the mold of FIGS. 1A and 1B taken alongline 4B-4B of FIG. 1B.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

FIGS. 1A-1D depict an embodiment 10 of the present molds for forming oneor more lenses. Mold 10 can comprise first and second mold portions 14 aand 14 b that are movable relative to one another between an openconfiguration (FIG. 1A) and a closed configuration (FIG. 1B). When moldportions 14 a and 14 b are in the closed configuration, complementaryrecesses 18 of the mold portions cooperate to define one or morechambers 26 (FIG. 1D). Mold 10 has a pair of cooling bodies 22 disposedin each of chamber(s) 26, one coupled to first mold portion 14 a and onecoupled to second mold portion 14 b. For example, for each of chamber(s)26, each of cooling bodies 22 can have a first face 56 coupled to arespective one of the mold portions. Each of the pair(s) of coolingbodies 22 is configured to receive inserts that can be used to form alens. To illustrate, each of the pair(s) of cooling bodies 22 can haveinserts 30 a and 30 b attached to a second face 58 of a respective oneof the cooling bodies (FIGS. 2 and 3A-3C), where the second face isopposite first face 56. As illustrated on FIGS. 2 and 3A-3C, each of theinserts 30 a and 30 b is in contact with the respective one of thecooling bodies to which it is attached exclusively by the second face 58of the respective one of the cooling bodies so as to provide goodperformance in terms of heat exchange as well as ease of manufacture.When mold portions 14 a and 14 b are in the closed configuration,inserts 30 a and 30 b cooperate to define a mold cavity 34 that canreceive moldable material. The received moldable material can solidifyto form a lens having a shape defined by mold cavity 34.

As shown, mold 10 can form multiple lenses simultaneously. Toillustrate, mold 10 can have eight chambers 26, each having a pair ofinserts 30 a and 30 b that cooperate to define a mold cavity 34. Each ofmold cavities 34 can receive moldable material that is injected intosprue 42 of first mold portion 14 a. When moldable material is injectedinto sprue 42, the material is conveyed to each of cavities 34 viarunner 40, which is defined by channels 38 of faces 62 a and 62 b of,respectively, mold portions 14 a and 14 b (FIGS. 1E and 1F). As such,eight lenses can be formed at once, one for each chamber 26. While mold10 defines eight chambers 26 when in the closed configuration, otherversions of the mold can define a different number of chambers. Forexample, other embodiments of mold 10 can define greater than or equalto, or between any two of: 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or morechambers. The appropriate number of chambers can be based in part onthroughput requirements.

Mold 10 can be used to form different lenses by using different inserts.Inserts, for example inserts 30 a and 30 b, can be detachable fromcooling bodies 22. Inserts attached to cooling bodies 22 can thereforebe readily interchanged with another pair of inserts that have adifferent shape and thus can be used to form a different lens. Suchinterchangeability eliminates the need for retooling.

In addition to providing insert interchangeability, cooling bodies 22can provide enhanced cooling capabilities for mold 10. Moldable materialinjected into mold cavity 34 is typically in a molten state and must becooled to solidify. Referring to FIG. 2, for each of chamber(s) 26, heatcan be transferred from moldable material disposed in mold cavity 34,through inserts 30 a and 30 b, and to each of cooling bodies 22. Coolingbodies 22 can accelerate such heat transfer with a coolant, such aswater or oil. To illustrate, for each cooling body 22, coolant can enterthe cooling body through inlet 46, flow to a fluid cavity 50 of thecooling body, and exit the cooling body through outlet 54. Fluidpassageways 48 can permit coolant to flow in this manner. Fluid cavity50 can be positioned and shaped, for example as an annulus, to promotedesirable flow characteristics and to facilitate heat transfer. Not tobe bound any particular theory, fluid cavity 50 can promote turbulenceand thereby improve the coolant's ability to collect heat. Additionally,fluid cavity 50 can be positioned proximate to second face 58 to whichan insert (e.g., 30 a or 30 b) is attached; in this manner, heattransferred from the moldable material and through the insert is readilycollected by the coolant in the fluid cavity. The coolant carries thecollected heat away from cooling body 22, thereby accelerating heattransfer and reducing the time required to form a lens. The reductionsin cycle time can be significant. For example, mold 10 can achieve atleast a 25% reduction in cycle time compared to molds that, whileotherwise similar, do not have cooling bodies.

Cooling bodies 22 can be used to achieve these reductions in cycle timewithout sacrificing insert interchangeability. Because coolant flowsthrough the structures of cooling bodies 22, and not inserts attached tothe cooling bodies, inserts used with the cooling bodies do not have tobe specially designed for mold 10. For example, an insert can beattached to second face 58 of one of cooling bodies 22 using existinginsert technology. As such, cooling bodies 22 can receive existinginserts such that mold 10 can be used without the added expense ofcustom inserts.

Cooling bodies 22 and inserts (e.g., 30 a and 30 b) used with thecooling bodies can comprise thermally conductive materials thatencourage rapid heat transfer from mold cavity 34. Such thermallyconductive materials can include metals, such as steel, copper,aluminum, or the like. As an example, at least a portion of each coolingbody 22—such as that in which fluid cavity 50 is defined—and/or aninsert attachable to the cooling body (e.g., 30 a or 30 b) can comprisea copper alloy or aluminum, which have relatively high thermalconductivities. Nevertheless, the insert and/or at least some portionsof the cooling body can comprise steel.

Cooling bodies 22 and inserts configured to be attached thereto canalternatively, or additionally, comprise non-metals that haveappropriate thermal and strength properties for use in mold 10. Forexample, inserts (e.g., 30 a and 30 b) can be manufactured from siliconcarbide (SiC). A description of illustrative formulations of SiC andillustrative methods of producing SiC can be found in Properties andCharacteristics of Silicon Carbide by Poco Graphite, Inc. (A. H. Rasheded.) (2002), which is hereby incorporated by reference. Silicon carbideinserts can have high conductivity, low expansion, and moderate to highthermal capacitance compared to inserts made with conventionalmaterials. Such properties can enhance the optical quality of lensesformed with SiC inserts. Silicon carbide used to make inserts can bedensified to decrease the porosity of the material. Densification caninclude the addition of a dense SiC coating using chemical vapordeposition (CVD) technology, and can additionally, or alternatively,include doping SiC with materials such as titanium, silicon, and/orboron. Silicon carbide can also be suitable for use in other componentsof mold 10, for example, without limitation, cooling bodies 22, channels38, body 70 (described below), and/or conduits 66 a and 66 b (describedbelow). Using SiC to make at least some of these components can furtherpromote reduced cycle times over conventional molds. In someembodiments, these components and/or inserts attached to cooling bodies22 can comprise a SiC coating disposed on a substrate, which cancomprise, for example, any of the metals described above. In someembodiments, these components and/or inserts attached to cooling bodies22 can comprise a SiC.

Cooling bodies 22 can be used in a mold having insert-ejectcapabilities. To illustrate, and referring to FIGS. 3A-3C, second moldportion 14 b can be an ejector mold. After a moldable materialsolidifies in each of mold cavit(ies) 34 (FIG. 3A), mold portions 14 aand 14 b can be moved to the open configuration (FIG. 3B). When moldportions 14 a and 14 b are moved thereto, the solidified material canremain attached to the second mold portion. To eject the solidifiedmaterial, each of cooling bod(ies) 22 of second mold portion 14 b can bemoved relative to its respective recess 18 towards face 62 b (FIG. 3C).When the cooling body is so moved, each of the insert(s) coupled tosecond mold portion 14 b extends, at least partially, beyond face 62 bsuch that the solidified material is ejected from the mold.

Conduits 66 a and 66 b of mold portions 14 a and 14 b, respectively, cantransfer coolant to and from cooling bodies 22. The followingdescription of conduits 66 a and 66 b is made with reference to moldportions that have multiple cooling bodies. For each mold portion (e.g.,14 a or 14 b), the manner in which conduits (e.g., 66 a or 66 b) connectcooling bodies 22 of the mold portion can be dictated in part by themold portion's physical constraints and functional requirements. Toillustrate, and referring to FIG. 4A, because cooling bodies 22 of firstmold portion 14 a—and thus conduits 66 a—do not need to be movable, theconduits can be defined within a fixed body 70. Additionally, fewcomponents of mold portion 14 a constrain the arrangement of conduits 66a; for example, sprue 42 can be the principal component that limits theconfiguration thereof, allowing the conduits to be arranged in a numberof suitable manners. As shown, conduits 66 a can connect cooling bodies22 such that, when coolant is received through inlet 74 a (e.g., from acoolant source (not shown) through supply conduit 78 a), the conduitsdirect the coolant to each cooling body in parallel. Coolant exitingeach cooling body 22 similarly is directed by conduits 66 a, inparallel, to exhaust 86 a (e.g., to exit through exhaust conduit 82 a).Such parallel connections can facilitate improved heat transfer. Not tobe bound by any particular theory, coolant that flows through coolingbodies 22 in series is less able to absorb heat as the coolant collectsheat from each cooling body. Parallel connections can avoid this effect.

Referring to FIG. 4B, second mold portion 14 b can impose greaterconstraints on the configuration of conduits 66 b. Because second moldportion 14 b has insert-eject functionality, conduits 66 b areconfigured to accommodate movement of the cooling bodies within recesses18. As shown, conduits 66 b can be internal hoses that travel withcooling bodies 22 when solidified material is ejected from mold portion14 b (FIGS. 3B and 3C). Conduits 66 b can be arranged such that, when somoved, the conduits are not impinged by and do not interfere withstructural components of second mold portion 14 b (e.g., movablesupports 90). To achieve such an arrangement, conduits 66 b can connectone or more sets of cooling bodies 22 in series. By way of example, andas depicted, second mold portion 14 b can have two sets of four coolingbodies 22 connected in series. For each of the set(s), coolant receivedfrom a coolant source (not shown) through a supply conduit 78 b can flowconsecutively between cooling bodies 22 via conduits 66 b before exitingsecond mold portion 14 b through exhaust conduit 82 b. Althoughconnecting cooling bodies 22 in series can reduce their ability to coolmoldable material injected into mold cavities 34 (as discussed above),using multiple sets can mitigate this effect.

Conduits 66 a and 66 b can be configured such that each pair of coolingbodies 22 facilitates similar rates of heat transfer through insert 30 aand insert 30 b. Such uniform cooling can promote good optics for a lensformed in mold cavity 34. Uniform cooling can be accomplished bymaintaining a similar coolant flow rate through the cooling bodies offirst mold portion 14 a (hereinafter “A-side flow rate”) and the coolingbodies of second mold portion 14 b (hereinafter “B-side flow rate”).Conduits 66 a and 66 b can be sized appropriately to reduce differencesbetween the A-side and B-side flow rates that may result from designvariations between mold portions 14 a and 14 b. Not to be bound by anyparticular theory, cooling bodies connected in series (e.g., those ofsecond mold portion 14 b), all else being equal, tend to experiencereductions in flow rate compared to cooling bodies connected in parallel(e.g., those of first mold portion 14 a). Conduits 66 b can accordinglybe sized to improve the B-side flow rate, which might otherwise be lowerthan the A-side flow rate because cooling bodies 22 of second moldportion 14 b are connected in series. For example, conduits 66 b caneach have a diameter larger, such as one that is at least 10%, 20%, 30%,40%, 50%, 60%, 70%, 80%, 90%, or 100% larger, than the diameters ofconduits 66 a. Additionally, or alternatively, the aggregate length ofconduits 66 b can be shorter, such as one that is at least 10%, 20%,30%, 40%, 50%, 60%, 70%, 80%, or 90% shorter, than the aggregate lengthof conduits 66 a. Sizing conduits 66 b in this manner can encourage moreequal A-side and B-side flow rates, which otherwise might besignificantly different due to the differences between mold portions 14a and 14 b. Conduits 66 a and 66 b thus can accommodate the differentphysical constraints and functional requirements of mold portions 14 aand 14 b while providing for substantially uniform cooling to maintaingood lens quality.

While mold portions 14 a and 14 b, as shown, have cooling bodies 22connected in parallel and series, respectively, other versions of mold10 can have mold portions that are configured differently. A moldportion (e.g., 14 a or 14 b) can have conduits that connect coolingbodies (e.g., 22) in any suitable manner—whether in parallel, series, ora combination thereof—to comply with the physical constraints andfunctional requirements of the mold portion. For example, while conduits66 a of first mold portion 14 a can connect cooling bodies 22 of themold portion in parallel, in other embodiments the conduits can connectthe cooling bodies in series. Likewise, although as shown conduits 66 aare defined by body 70 and conduits 66 b are hoses, the conduits can beany suitable conduits such as, for example, pipes, hoses, channelsdefined in a body, and/or the like. By way of example, conduits 66 a offirst mold portion 14 a can comprise pipes and/or hoses, and conduits 66b can be defined within a body (e.g., 70) that is configured to movewith cooling bodies 22 when moldable material is ejected from mold 10.And while conduits 66 b, as shown, have a larger diameter and/or shorteraggregate length than conduits 66 a, in other embodiments conduits 66 bcan have a smaller diameter and/or longer aggregate length than conduits66 a, or the conduits can be similarly sized. For example, if moldportions 14 a and 14 b have similar configurations of cooling bodies,similar A-side and B-side flow rates may be achievable with similarlysized conduits.

Some embodiments of the present methods comprise a step of moving afirst mold portion (e.g., 14 a) and a second mold portion (e.g., 14 b)relative to one another from an open configuration (FIG. 1A) to a closedconfiguration (FIG. 1B). When in the closed configuration, the moldportions can cooperate to define one or more chambers (e.g., 26) thateach have a pair of cooling bodies (e.g., 22), for example as describedabove with respect to mold 10.

Some methods comprise a step of attaching a pair of inserts (e.g., 30 aand 30 b) to each of the pair(s) of cooling bodies before moving themold portions to the closed configuration. Each of the pair(s) ofinserts can cooperate to define a mold cavity (e.g., 34) when the moldportions are in the closed configuration. As described above, differentpairs of inserts—each configured to define a cavity having a differentshape—can be used with the mold; some methods comprise a step of, forone or more of the pair(s) of cooling bodies, changing a pair of insertsattached thereto for a different pair of inserts. Changing can comprisedetaching the first pair of inserts from the cooling bodies andattaching the second pair of inserts thereto without placing the insertsin fluid communication with the cooling bodies. In some methods, wherethe mold portions define multiple chambers, the pairs of insertsattached to the cooling bodies are the same; nevertheless, in othermethods, the above steps can be performed such that different pairs ofinserts are used in the mold simultaneously.

Some embodiments of the present methods comprise a step of injectingmoldable material into the one or more mold cavities defined by theinserts. Injecting can comprise introducing moldable material into asprue (e.g., 42) of the first mold portion and conveying the moldablematerial via a runner (e.g., 40) to each of the chamber(s), where themoldable material is received into the mold cavity defined by theinserts disposed therein. Some of the present methods comprise a step ofcooling the received moldable material with the cooling bodies. Coolingcan be performed until the moldable material solidifies to form aproduct, such as a lens. For each of the cooling bodies, cooling cancomprise receiving coolant at the inlet (e.g., 46) of the cooling body,conveying the coolant to a fluid cavity (e.g., 50), and conducting heatfrom the moldable material to the cooling body. The heat can beconducted through the insert attached to the cooling body and can heatthe coolant. Cooling can further comprise, for each of the coolingbodies, transmitting the heated coolant through the outlet (e.g., 54) ofthe cooling body such that the coolant carries the heat away andaccelerates cooling. Cooling can be performed such that the A-side flowrate is within 10%, for example less than or substantially equal to, orbetween any two of: 10%, 8%, 6%, 4%, or 2%, of the B-side flow rate.Such relative A-side and B-side flow rates can be accomplished by usingappropriately sized conduits (e.g., 66 a and 66 b, as described above)and/or by supplying coolant at the appropriate pressures to each of themold portions.

As described above, in embodiments where the mold portions definemultiple chambers, the first mold portion can have cooling bodies(“A-side cooling bodies”) connected in parallel and the second moldportion can have one or more sets of cooling bodies (“B-side coolingbodies”) connected in series. Accordingly, in some methods, coolingcomprises receiving, at the inlets of at least two of the A-side coolingbodies, coolant from a common supply conduit, and further comprisesconveying the coolant through the outlets of the cooling bodies to acommon exhaust conduit. Likewise, in some methods, cooling comprises,for each of the set(s) of the B-side cooling bodies, transmittingcoolant consecutively through the cooling bodies such that fluidtransmitted from the outlet of one of the cooling bodies is received atthe inlet of at least one other of the cooling bodies.

Some embodiments of the present methods comprise a step of ejecting themoldable material after it solidifies. Ejecting can comprise moving themold portions to the open configuration such that the moldable materialis coupled to the insert(s) attached to the B-side cooling bod(ies).When the mold portions are in the open configuration, ejecting canfurther comprise moving each of the B-side cooling bod(ies) towards theface of the second mold portion (e.g., 62 b) such that the insertattached thereto extends at least partially beyond the face and themoldable material is ejected.

Moldable material suitable for use in the present molds and methods cancomprise thermoplastics, glasses, metals, elastomers, and/or the like.Examples of suitable plastics include, for example, acrylonitrilebutadiene styrene, polypropylene, polyoxmethylene, polycarbonate,polyvinyl chloride, nylon, acrylic, styrene, polyether imide, or acombination thereof. The selection of a moldable material can be basedin part on the desired characteristics of a product to be formed. Forexample, a transparent moldable material may be suitable for forminglenses. While some embodiments are described with reference to insertsthat can be used to form lenses, some of the present molds and methodscan be used with inserts configured to make other products. Non-limitingexamples of such products include, for example, containers, lids,switches, toys, medical devices, automotive parts, handles, knobs,tools, hardware, plugs, and/or the like. Coolant suitable for use in thepresent molds and methods can comprise any suitable fluid, includingliquids and gases. For example, and without limitation, suitablecoolants can include water, oils, air, hydrogen, and/or the like.

The above specification and examples provide a complete description ofthe structure and use of illustrative embodiments. Although certainembodiments have been described above with a certain degree ofparticularity, or with reference to one or more individual embodiments,those skilled in the art could make numerous alterations to thedisclosed embodiments without departing from the scope of thisinvention. As such, the various illustrative embodiments of the methodsand systems are not intended to be limited to the particular formsdisclosed. Rather, they include all modifications and alternativesfalling within the scope of the claims, and embodiments other than theone shown may include some or all of the features of the depictedembodiment. For example, elements may be omitted or combined as aunitary structure, and/or connections may be substituted. Further, whereappropriate, aspects of any of the examples described above may becombined with aspects of any of the other examples described to formfurther examples having comparable or different properties and/orfunctions, and addressing the same or different problems. Similarly, itwill be understood that the benefits and advantages described above mayrelate to one embodiment or may relate to several embodiments.

The claims are not intended to include, and should not be interpreted toinclude, means-plus- or step-plus-function limitations, unless such alimitation is explicitly recited in a given claim using the phrase(s)“means for” or “step for,” respectively.

1. A mold comprising: first and second mold portions, each having one ormore recesses, wherein the mold portions are movable relative to oneanother between an open position and a closed position in which each ofthe recess(es) of the first mold portion cooperates with a respectiveone of the recess(es) of the second mold portion to define a chamber,wherein each of the one or more chambers comprises a first cooling bodycoupled to the first mold portion and a second cooling body coupled tothe second mold portion, wherein a first insert is configured to beremovably coupled to the first cooling body and a second insert isconfigured to be removably coupled to the second cooling body such that,when the first and second inserts are respectively removably coupled tothe first and second cooling bodies, the first insert and the secondinsert cooperate to define a mold cavity within the chamber that isconfigured to receive a thermoplastic material; wherein each of thefirst and second cooling bodies comprises a thermally-conductivematerial, each of the first and second cooling bodies comprisingopposing first and second faces and an inlet and an outlet, wherein thefirst face is coupled to one of the mold portions and the second face isconfigured to be removably coupled to one of the first and secondinserts, wherein each of the first and second cooling bodies defines afluid cavity closer to the second face than the first face, and whereinthe fluid cavity is in fluid communication with the inlet and theoutlet.
 2. The mold of claim 1, wherein the chamber(s) comprise two ormore chambers, and wherein for each of one or more sets of a pluralityof the chambers: the first cooling bodies are in fluid communicationwith one another via one or more first conduits, each of the firstconduit(s) having a first diameter; the second cooling bodies are influid communication with one another via one or more second conduits,each of the second conduit(s) having a second diameter; and the seconddiameter is at least 20% larger than the first diameter.
 3. The mold ofclaim 2, wherein for each of the set(s) of the chambers the firstcooling bodies are connected in parallel such that: the inlet of each ofthe first cooling bodies is coupled to a common supply conduit in fluidcommunication with a fluid source; and the outlet of each of the firstcooling bodies is coupled to a common exhaust conduit in fluidcommunication with an exhaust.
 4. The mold of claim 2, wherein for eachof the set(s) of the chambers the second cooling bodies are connected inseries such that: a supply conduit in fluid communication with a fluidsource is coupled to the inlet of one of the second cooling bodies; anexhaust conduit in fluid communication with an exhaust is coupled to theoutlet of one of the second cooling bodies; and one or more conduits aredisposed between the second cooling bodies such that when fluid flowsfrom the supply conduit, the fluid flows consecutively through each ofthe second cooling bodies before flowing through the exhaust conduit. 5.The mold of claim 4, wherein the chambers comprise three or morechambers, and wherein at least one of the set(s) of the chamberscomprises three or more of the second cooling bodies connected inseries.
 6. The mold of claim 2, wherein: the set(s) of the chamberscomprise two or more sets of the chambers; and the second cooling bodiesof at least one of the sets are not in fluid communication with thesecond cooling bodies of other ones of the sets.
 7. The mold of claim 1,wherein each of the one or more second cooling bodies is movable withina respective recess of the second mold portion between a first positionand a second position in which the second cooling body is closer thanwhen in the first position to the face of the second mold portion that,when the mold portions are in the closed position, faces the first moldportion.
 8. The mold of claim 1, comprising one or more of the firstinserts and one or more of the second inserts wherein each of the firstand second inserts comprises silicon carbide and, for each of thechamber(s), one of the first insert(s) is coupled to the first coolingbody and one of the second insert(s) is coupled to the second coolingbody.
 9. A method for creating one or more optical articles, the methodcomprising: moving a first mold portion and a second mold portionrelative to one another from an open position to a closed position inwhich the mold portions cooperate to define one or more chambers,wherein each of the chamber(s) comprises a first cooling body coupled tothe first mold portion, a second cooling body coupled to the second moldportion, a first insert removably coupled to the first cooling body, anda second insert removably coupled to the second cooling body such thatthe first and second inserts cooperate to define a mold cavity;receiving, at each of the one or more mold cavities, a thermoplasticmaterial; and cooling the received thermoplastic material with the firstand second cooling bodies, wherein each of the first and second coolingbodies comprises opposing first and second faces and an inlet and anoutlet, wherein the first face is coupled to one of the mold portionsand the second face is removably coupled to one of the first and secondinserts, wherein each of the first and second cooling bodies defines afluid cavity closer to the second face than the first face, and whereincooling comprises, at each of the first and second cooling bodies:receiving, at the inlet, fluid from a fluid source; conveying thereceived fluid to the fluid cavity; conducting, through one of the firstand second inserts, heat from the thermoplastic material to the coolingbody to thereby heat the conveyed fluid; and transmitting, through theoutlet, the heated fluid outside of the cooling body.
 10. The method ofclaim 9, wherein the one or more chambers comprise two or more chambers,and cooling comprises: receiving, at the inlet of at least two of thefirst cooling bodies, fluid from a common supply conduit; and conveying,to an exhaust, fluid from the outlet of at least two of the firstcooling bodies along a common exhaust conduit.
 11. The method of claim9, wherein the one or more chambers comprise two or more chambers, andcooling comprises receiving, at the inlet of at least one of the secondcooling bodies, fluid conveyed from the outlet of another one of thesecond cooling bodies.
 12. The method of claim 9, comprising: beforemoving the first and second mold portions, for at least one of thechamber(s): decoupling a third insert from the first cooling body;decoupling a fourth insert from the second cooling body; removablycoupling the first insert to the first cooling body; and removablycoupling the second insert to the second cooling body; wherein the thirdand fourth inserts are configured to cooperate to define a mold cavityhaving a shape different from a shape of the mold cavity defined by thefirst and second inserts; and wherein the coupling is performed withoutplacing the first and second inserts in fluid communication with thefirst and second cooling bodies.
 13. The method of claim 9, whereincooling is performed until the thermoplastic material solidifies. 14.The method of claim 13, comprising: moving the first mold portion andthe second mold portion relative to one another from the closed positionto the open position in which, for each of the one or more secondcooling bodies, the solidified thermoplastic material is coupled to thesecond insert; and for each of the one or more second cooling bodies:moving the second cooling body, relative to the second mold portion,closer to the face of the second mold portion that, when the moldportions are in the closed position, faces the first mold portion; andejecting the solidified thermoplastic material from the second insert.15. The method of claim 9, wherein cooling comprises, for each of theone or more chambers, receiving fluid at the inlet of the first coolingbody at a rate within 10% of the rate at which fluid is received at theinlet of the second cooling body.
 16. The mold of claim 1, wherein thechamber(s) comprise two or more chambers, and wherein for each of one ormore sets of a plurality of the chambers: the first cooling bodies arein fluid communication with one another via one or more first conduits,each of the first conduit(s) having a first diameter; and the secondcooling bodies are in fluid communication with one another via one ormore second conduits, each of the second conduit(s) having a second. 17.The mold of claim 3, wherein for each of the set(s) of the chambers thesecond cooling bodies are connected in series such that: a supplyconduit in fluid communication with a fluid source is coupled to theinlet of one of the second cooling bodies; an exhaust conduit in fluidcommunication with an exhaust is coupled to the outlet of one of thesecond cooling bodies; and one or more conduits are disposed between thesecond cooling bodies such that when fluid flows from the supplyconduit, the fluid flows consecutively through each of the secondcooling bodies before flowing through the exhaust conduit.
 18. The moldof claim 3, wherein: the set(s) of the chambers comprise two or moresets of the chambers; and the second cooling bodies of at least one ofthe sets are not in fluid communication with the second cooling bodiesof other ones of the sets.
 19. The mold of claim 4, wherein: the set(s)of the chambers comprise two or more sets of the chambers; and thesecond cooling bodies of at least one of the sets are not in fluidcommunication with the second cooling bodies of other ones of the sets.20. The mold of claim 5, wherein: the set(s) of the chambers comprisetwo or more sets of the chambers; and the second cooling bodies of atleast one of the sets are not in fluid communication with the secondcooling bodies of other ones of the sets.